Ozair Iqbal

Key Achievements

• Commissioned Ammonia Pre-heater at Urea plant, resulting in substantial decrease in steam consumption per metric ton of Urea - Annual savings of ~146 Million PKR
• Planned and coordinated 20-day Urea Plant Turnaround in 2022, achieving energy reduction of 0.14 GCal per metric ton of Urea
• Troubleshooted and identified leaked Ammonia Pre-heater resulting in decreased Ammonia losses worth 0.84 Million PKR in 2022
• Working on ongoing Green Six Sigma Project at Plant site, to reduce daily consumable items for whole plant site - Projected scope of ~3 Million PKR
• Commissioned Gas Engine Driven PD compressors (EOR 33 MMSCFD) at offsite Gas Compression Facility of FFC, resulting in 6% increase in Plant load
• Commissioning of Reverse Osmosis Unit at Gas Compression Facility of FFC
• Improved SAP PP & PM module in liaison with IT and Process Engineering, for effective reporting of energy figures & improve data collection of breakdowns respectively.
• IFA Product Stewardship (Protect & Sustain) certification gap analysis and subsequent implementation of certification requirements at Ammonia & Urea Plants in 2017

Responsibilities:

• Report production parameters on SAP-Production Planning module followed by analysis and optimization of plant parameters.
• Ensure implementation of routine monitoring program for fugitive emissions detection and initiate timely repairs (LDAR).
• Collaborate with Maintenance agencies to implement and improve corrective and preventive maintenance through SAP PM Module, and regularly analyze SAP BI reports.
• Coordinate with HSE&Q for reporting environmental and safety incidents/emissions.
• Manage hot & cold startups and shutdowns
• Handle emergency situations and troubleshoot various process upset events for Gas Compression, Ammonia & Urea Unit.
• Efficiently troubleshoot multiple emergencies and plant trips to avoid recurrence
• Act as first responder to Ammonia leakages and warden of fire-fighting team.
• Simulate Plant conditions and monitor machines performance using Aspen HYSIS and Ariel Performance Program.
• Prepare OPEX budgets including quantity planning (Chemicals, catalyst and Natural Gas etc.) and cost center budget planning
• Prepare CAPEX investments proposals for subsequent review to board members
• Analyzing quarterly expense reports for variance and optimization of budgets
• Generate operational flexibility vs cost-cutting reports.
• Auditor/Auditee for internal and external ISO audits.
• Update operational procedures in accordance with any changes at plant modifications and practices.
• Provide assistance to Process Engineering for updating Urea Plant P&IDs
• Prepare proposals for new modifications and solutions for recurring issues. Tracking of Follow up of Management of Change (MOC) workflow.
• Developed and maintained standardized operating procedures for numerous functions and tasks to streamline operations.
• Skilled in accounting of Green House Gas (Co2) in Ammonia production.

• Maintained compliance with test center policies, practices and procedures.
• Secured testing materials and maintained confidentiality of all details.
• Maintained secure and positive environment conducive to testing.

• Buying of maximum value pharmaceutical and surgical products from local market.
• Sourced and vetted new vendors to meet purchasing needs.
• Analyzed market to assess present and future material availability.
• Part time evening job with studies.